Pallet

ABSTRACT

A pallet provides reinforced columns and a more resilient periphery of the upper deck. The pallet includes an upper portion having an upper deck and a lower portion, which may include runners. A plurality of outer column portions have peripheral walls extending from the upper portion to the lower portion. A plurality of inner column portions are received within the outer column portions.

This application claims priority to U.S. Provisional Application Ser. No. 61/327,066 filed Apr. 22, 2010.

BACKGROUND

Plastic pallets may include an upper deck and a lower deck (or runners) with columns between the upper deck and the runners to provide openings for receiving the tines of a forklift. The columns and the outer periphery of the upper deck often are impacted by the tines of the forklift Therefore, the columns and outer periphery of the upper deck suffer most of the damage experienced by plastic pallets.

SUMMARY

A pallet according to one embodiment of the present invention provides reinforced columns and a more resilient periphery of the upper deck. The pallet includes an upper portion having an upper deck and a lower portion, which may include runners. A plurality of outer column portions have peripheral walls extending from the upper portion to the lower portion.

A plurality of inner column portions are received within the outer column portions. Each inner column portion may include a plurality of projections on an outer edge of the inner column portion.

The pallet may include at least one reinforcement member, in which case the plurality of projections are spaced apart to provide inner channels and outer channels formed through the outer column portions.

The plurality of outer column portions may include a plurality of tabs received in openings adjacent the inner column portions. A shoulder portion may be formed adjacent each inner column portion, wherein the openings are formed in the shoulder portions.

The inner column portions may be formed integrally with the lower portion and the outer column portions may be formed integrally with the upper portion.

The upper deck includes a plurality of ribs formed on the underside. A periphery of the upper deck may include ribs in a honeycomb pattern, to provide a more resilient area. The periphery is more resistant to damage from fork tine impact.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a pallet according to one embodiment of the present invention.

FIG. 2 is a perspective view of the lower portion of the pallet of FIG. 1.

FIG. 3 is the lower portion of FIG. 2 with reinforcement bars received thereon.

FIG. 4 is a perspective view of the upper portion.

FIG. 5 is an exploded view of the pallet.

FIG. 6 is a bottom perspective view of the lower portion.

FIG. 7 is a bottom perspective view of the upper portion.

FIG. 8 is another bottom perspective view of the upper portion.

FIG. 8A is an enlarged view of one of the columns .

FIG. 8B is a section view through half of one of the columns.

FIG. 9 is a top view of the upper portion.

FIG. 10 is a bottom view of the upper portion.

FIG. 11 is a top view of the lower portion.

FIG. 12 is a bottom view of the lower portion.

FIG. 13 is a bottom view of the pallet.

FIG. 14 is a side view of the pallet.

FIG. 15 is an end view of the pallet.

DETAILED DESCRIPTION

A pallet 10 according to one embodiment of the invention is shown in FIG. 1. The pallet 10 generally includes an upper portion 12 having an upper deck 14 and outer column portions 20 extending downwardly from the upper deck 14. The pallet 10 further includes a lower portion 18 having runners 22 (or lower deck) extending between the outer column portions 20.

FIG. 2 is a perspective view of the lower portion 18. As shown, the lower portion 18 includes a plurality of inner column portions 21 extending upwardly at the intersections of the runners 22. The inner column portions 21 and runners 22 in this embodiment are all integrally molded as a single piece. Each inner column portion 21 includes a plurality of upward projections 26 about the periphery of the upper edge of the inner column portion 21. The projections 26 are offset inwardly from the periphery of the inner column portion 21 to form a shoulder 28 around the periphery of the upper edge of the inner column portion 21.

As shown in FIG. 3, reinforcement bars 30 may optionally be provided. The projections 26 on each inner column portion 21 are spaced apart to provide channels in which the reinforcement bars 30 can be received. The reinforcement bars 30 can be metal, steel, aluminum, or composite polymers, such as fiberglass reinforced polymers. The reinforcement bars 30 rest on the inner column portions 21 between the projections 26.

FIG. 4 is a perspective view of the upper portion 12. As shown, each outer column portion 20 includes a plurality of optional tabs 32 projecting downwardly from the lower most edge of each outer column portion 20.

FIG. 5 is an exploded view of the pallet 10 showing the relative relationships of the upper portion 12, lower portion 18 and optional reinforcement bars 30 therebetween.

FIG. 6 is a bottom perspective view of the lower portion 18. Ribs project downwardly from the lower portion 18, including from the runners 22. The inner column portions 21 and the projections 26 are shown.

FIG. 7 is a bottom perspective view of the upper portion 12. The bottom of the deck 14 is provided with a plurality of intersecting ribs for reinforcement. For example, lateral and longitudinal ribs extend between each adjacent pair of outer column portions 20 and diagonal ribs extend between each diagonally opposed pair of outer column portions 20. However, around the periphery of the deck 14 is a resilient section 34 including a plurality of ribs 36 arranged in a honeycomb pattern. Thus, while the lateral, longitudinal and diagonal ribs in a central portion of the deck 14 between the outer column portions 20 provide stiffness to the deck 14 and does not have a honeycomb pattern, the resilient section 34 around the outer periphery of the deck 14 permits the periphery of the deck 14 to flex in response to impacts along the periphery of the deck 14 in a direction substantially parallel to the plane of the deck 14.

As can also been seen in FIG. 7, the outer column portions 20 each include gaps or channels 38 therethrough for accommodating the reinforcement bars 30 (FIG. 5).

FIG. 8 is another bottom perspective view of the upper portion 12.

FIG. 8A is an enlarged view of one of the outer column portions 20 of FIG. 8. Within each of the outer column portions 20 is a plurality of ribs 40 between the peripheral walls of the outer column portions 20. Further, a plurality of cantilevered latches 42 project downwardly within the outer column portion 20. In the embodiment shown, the latches 42 are stiffened by large ribs projecting from the rear of the latches 42.

FIG. 8B is a section view through half of the center column of the pallet 10. When assembled, the inner column portions 21 of the lower portion 18 are received within the outer column portions 20 of the upper portion 12 to form columns between the upper deck 14 and the runners 22 (or lower deck). Portions of the ribs 40 of the upper portion 12 abut the shoulder 28 of the inner column portion 21. The latches 42 projecting downwardly within the outer column portion 20 snap-fit under the projections 26 of the inner column portion 21 to thereby secure the upper portion 12 to the lower portion 18. Further, the tabs 32 at the lower edges of the outer column portions 20 are received within slots (or openings) formed on a lower shoulder 46 of the inner column portions 21. A tapered portion 48 leads away from the lower shoulder 46 to the runner 22. In this manner, the pallet 10 is provided with significantly reinforced outer column portions 20, which are reinforced by the inner column portions 21. This reinforcement protects the outer column portions 20 in the event of impact, such as by the tines of a fork-lift.

FIG. 9 is a top view of the upper portion 12 and upper deck 14. FIG. 10 is a bottom view of the upper portion 12. FIG. 11 is a top view of the lower portion 18. FIG. 12 is a bottom view of the lower portion 18. FIG. 13 is a bottom view of the pallet 10 including the lower portion 18 and upper portion 12. FIG. 14 is a side view of the pallet 10. FIG. 15 is an end view of the pallet 10.

In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent a preferred embodiment of the invention. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. For example, although the inner column portion 21 is shown as formed integrally with the lower portion 18, and the outer column portion 20 with the upper portion 12, the inner column portion 21 could be formed integrally with the upper portion 12 and the outer column portion 20 could be formed integrally with the lower portion 18. 

1) A pallet comprising: an upper portion having an upper deck; a lower portion; and a plurality of columns formed between the upper deck and the lower portion, each of the plurality of columns including an inner column portion formed integrally with one of the upper portion and the lower portion and an outer column portion formed integrally with the other of the upper portion and the lower portion, the inner column portions received within the outer column portions. 2) The pallet of claim 1 wherein the inner column portions each include a plurality of projections offset inwardly from a periphery of the inner column portion to form a shoulder around the periphery of an upper edge of the inner column portion. 3) The pallet of claim 2 wherein the plurality of projections are spaced apart to provide a channel, the pallet further including at least one reinforcement member received in the channel. 4) The pallet of claim 3 wherein the plurality of outer column portions include channels therethrough, the reinforcement member received in the channels. 5) The pallet of claim 1 wherein each of the plurality of outer column portions includes a plurality of tabs received in openings adjacent the inner column portions. 6) The pallet of claim 5 further including a shoulder portion adjacent each inner column portion, wherein the openings are formed in the shoulder portions. 7) The pallet of claim 6 wherein the inner column portions are formed integrally with the lower portion and wherein the outer column portions are formed integrally with the upper portion. 8) The pallet of claim 1 wherein the inner column portions are formed integrally with the lower portion and wherein the outer column portions are formed integrally with the upper portion. 9) The pallet of claim 8 wherein the lower portion includes a plurality of runners, wherein the columns extend from intersections of the plurality of runners. 10) The pallet of claim 1 wherein the upper deck includes a plurality of ribs, the upper deck including a peripheral portion in which the plurality of ribs are arranged in a honeycomb pattern. 11) The pallet of claim 1 wherein the outer column portions each include a peripheral wall having a plurality of ribs along an interior surface of the peripheral wall. 12) The pallet of claim 11 further including a plurality of latches formed within the outer column portions, wherein the plurality of latches snap fit to connect to the inner column portions. 13) A pallet comprising: an upper portion having an upper deck; a lower portion; a plurality of outer column portions having peripheral walls with outer channels therethrough, the outer column portions extending from the upper portion to the lower portion; a plurality of inner column portions each including a plurality of projections on an outer edge of the inner column portion, the plurality of projections spaced apart to provide inner channels, each inner column portion received within one of the outer column portions; and at least one reinforcement member received in the inner channels and the outer channels. 14) The pallet of claim 13 wherein each of the plurality of outer column portions includes a plurality of tabs received in openings adjacent the inner column portions. 15) The pallet of claim 14 further including a shoulder portion adjacent each inner column portion, wherein the openings are formed in the shoulder portions. 16) The pallet of claim 15 wherein the inner column portions are formed integrally with the lower portion and wherein the outer column portions are formed integrally with the upper portion. 17) A pallet comprising: a deck, wherein the deck includes a panel portion and a plurality of ribs extending downward from an underside of the panel portion, the deck including a central portion and a peripheral portion, wherein the plurality of ribs in the peripheral portion have a honeycomb pattern; and a plurality of columns extending downward from the upper deck. 18) The pallet of claim 17 wherein the plurality of ribs in the central portion do not have a honeycomb portion. 